Exploring plate heat exchanger trends in Canadian food processing plants
Discover how your plate heat exchanger maintenance, service and usage compare to other Canadian food processing plants.
DATE 2024-07-16It's no secret that food processing is hugely important to the Canadian economy. Not only for the convenience, variety and sometimes pure joy we derive from the end products (we're looking at you, ice cream), but because many international food processing companies are invested and active in Canada, including PepsiCo, Kraft Heinz, Parmalat and Nestlé.
Among Canadian companies, Saputo, which focuses on dairy products, is one of the largest operators, with an annual revenue of almost $18 million in 2023. Like the rest of our food processing industry, it adheres to stringent quality standards, is committed to innovation, and relies heavily on advanced technologies like plate heat exchangers to meet and exceed regulatory requirements and consumer expectations.
It's no surprise, then, that proper plate heat exchanger maintenance and optimization strategies are crucial for food processing plants. In our benchmark report, we surveyed a wide range of industrial manufacturers in Canada. In this blog, we will explore how those working in Canadian food processing plants told us how they used, serviced and maintained their plate heat exchangers.
Optimizing performance: Benchmarking insights into plate heat exchanger maintenance and service
Learn how to maximize your heat exchangers' efficiency and minimize downtime in your facility.
Who Did We Survey?
Our survey encompassed a diverse range of respondents from different roles within food processing plants across Canada. The majority (almost 40%) are in Quebec, followed closely by Ontario (32%). British Columbia was next at 16%, but Alberta (8%), Manitoba (3%) and Saskatchewan (3%) were the minority.
In terms of job title, most of the people who responded held the title of Plant Manager (22%), Plant General Manager (16%) or Plant Operations Manager (16%), which tells us that they are directly involved with the day-to-day operations and management of the plant. Only 5% worked in the C-suite.
Harnessing the Heat
How many food processing plants are using plate heat exchangers? A lot, it turns out. 76% of our respondents confirmed they used plate heat exchangers, underscoring these systems' pivotal role in supporting essential operations within the agricultural processing domain. In terms of specific usage, 43% use them for heat recovery, 35% use them for heating and 21% use them for cooling.
Heat exchangers are extremely important for a variety of applications in the food processing sector, including but not limited to:
- Sterilization: Vital for sterilizing equipment and maintaining hygiene in food processing plants.
- Cooking and Cooling: Enables rapid heating and cooling processes, optimizing production efficiency.
- Fluid Pasteurization: Used for pasteurizing liquids like milk and juice, maintaining product quality and extending shelf life.
Servicing Practices: A Breakdown
We then explored how food processing plants are servicing their plate heat exchangers, and whether they followed specific schedules and methods. Here's what we learned:
Maintenance Practices:
- 79% adhere to specific cleaning and maintenance schedules
- 46% of respondents clean or service at least once a year
- 25% of respondents clean or service every 1-4 years
- 4% of respondents clean or service every 5-7 years
Factors Influencing Cleaning Frequency:
- 54% cited cost considerations as a primary influencer
- 50% take operating hours into account
- 50% follow regulatory requirements
- 43% said it depends on the types of fluid processed
- 43% said performance changes drive cleaning
- 36% follow the manufacturer's recommended schedule
Cleaning Methods:
- 68% utilize high-pressure water jetting
- 43% opt for mechanical cleaning/brushing
- 36% utilize chemical cleaning
Cleaning Providers:
- 36% rely on the manufacturer
- 32% use a repair company
- 29% use a distributor
- 4% were unsure
Performance Measurement Practices:
- 50% use continuous data logging to measure performance
- 43% measure performance randomly
- 7% do not measure performance
The Advantages of Plate Heat Exchangers in Your Plant
Alfa Laval's products offer reliability, low operating costs, and superior performance in food processing plants. We offer a wide range of offerings tailored specifically for your sector, including (but not limited to):
Dairy Processing
Experience minimized fouling, superior cleanability, and simplified maintenance with Alfa Laval’s Hygienic line of plate heat exchangers. Optimized flow distribution and a smoother plate pattern improve heat transfer efficiency, improving energy efficiency by up to 15%. These features also contribute to lowering the pressure drop by up to 10% while enabling the heat exchanger to perform the same duty.
Plant-based Protein Processing
Alfa Laval is a key partner for plant and vegetable protein companies. Our Hygienic line of plate heat exchangers meets even the strictest hygienic control demands. Its specific fouling-resistant design allows for extended running time and is FCM-compliant.
Food Processing
From fat and oil processing to prepared food processing and more, Alfa Laval's Hygienic line of gasketed plate heat exchangers is FDA-compliant. Easy-opening gaskets simplify inspections and cleaning, and the flexible design allows the heat transfer area to be modified.
Protein Processing
Alfa Laval remains at the forefront of new production methods to support your animal and plant protein production operations. With our extensive line of gasketed plate heat exchangers, you can benefit from high efficiency and outstanding reliability in a compact design. With the most attractive CTO over the product's lifetime, you’ll find cost savings regardless of the kind of protein you’re working with.
Optimize Your Plant's Performance with Alfa Laval
Teaming up with Alfa Laval boosts your heat exchanger's performance and minimizes downtime; it also enhances your plant's operational efficiency.
Our integrated strategy includes specialized solutions for food processing, thorough efficiency assessments, practical training sessions emphasizing optimal operation and upkeep, and smooth access to top-notch replacement parts or upgrades as required.